A molding process for a low-wind-resistance, high-stability molecular sieve concentration rotor carrier

Abstract

This invention relates to the field of molecular sieve concentration rotor carrier molding process, which discloses a low-resistance, high-stability process. The process first uses wet papermaking to form an inorganic fiber composite base paper consisting of a rectifying layer and a skeleton layer. Then, under wet or semi-wet conditions, predetermined node and edge bands are subjected to strip compaction and inorganic sol impregnation treatment. Subsequently, a portion of the composite base paper is pressed into a corrugated sheet with peak-valley arc transitions, and alternately layered and wound with flat sheets to form a rotor carrier blank. Finally, under radial constraint, low-temperature pre-fixation, medium-temperature curing, and high-temperature final setting treatments are sequentially performed, and molecular sieve loading is applied to the main channel area. This invention can balance the low-resistance characteristics of the honeycomb airflow channel with the high stability of the carrier structure, and is suitable for the preparation of molecular sieve concentration rotor carriers.

Description

Technical Field

[0001] This invention relates to the field of volatile organic waste gas treatment, specifically to a molding process for a low-resistance, high-stability molecular sieve concentration rotor carrier. Background Technology

[0002] In the treatment of volatile organic waste gas, molecular sieve concentrators typically employ an axially continuous honeycomb channel structure, allowing the gas to be treated to pass through the carrier channel and contact the molecular sieve to achieve adsorption and concentration. This type of rotor has been widely used in continuous exhaust scenarios such as spraying and coating, which places high demands on the carrier's ventilation resistance, heat resistance, and cyclic operation stability.

[0003] Existing molecular sieve concentration rotor carriers are mostly prepared using inorganic fiber paper or molecular sieve paperboard routes. That is, wet paperboard is first formed by papermaking, then flat sheets and corrugated sheets are made, and then the two are alternately stacked or wound to form a honeycomb structure. Some schemes also impregnate the paperboard with silica sol or alumina sol, or improve the interlayer bonding strength and overall molding stability through drying, hot pressing, sintering and other methods.

[0004] However, most existing technologies revolve around the integral forming, impregnation, and shaping of the entire cardboard sheet. When strength is increased through integral compaction, impregnation, or densification, the pores in the channel walls are easily reduced and the surface roughness is increased, thereby increasing airflow resistance. On the other hand, when the degree of compaction is reduced or the integral bonding is weakened in order to reduce wind resistance, the interlayer bonding strength between the corrugated sheet and the flat sheet is easily insufficient, and problems such as edge deformation, local collapse, and decreased channel stability occur during winding, heat treatment, shaping, and subsequent heat recycling. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a low-wind-resistance, high-stability molecular sieve concentration rotor carrier molding process to solve the technical problems existing in the prior art.

[0006] The above-mentioned technical objective of the present invention is achieved through the following technical solution: A process for forming a low-wind-resistance, high-stability molecular sieve concentration rotor carrier includes the following steps: S1: Inorganic fiber composite base paper is prepared by wet papermaking process, so that the composite base paper forms a rectification layer and a skeleton layer along the thickness direction. The rectification layer is used to form the inner wall of the subsequent airflow channel, and the skeleton layer is used to form the subsequent carrier load-bearing layer. S2: When the composite base paper is in a wet or semi-wet state, localized reinforcement is applied to the predetermined node strip and predetermined edge strip. The predetermined node strip includes the strip-shaped area corresponding to the crest contact line and the strip-shaped area corresponding to the trough contact line of the subsequent corrugated sheet. The predetermined edge strip includes the area corresponding to the inner ring edge strip and the area corresponding to the outer ring edge strip after subsequent winding and forming. Localized reinforcement includes strip compaction of the predetermined node strip and predetermined edge strip, and impregnation of inorganic sol into the strip compaction area, so that the density of the predetermined node strip and predetermined edge strip is higher than that of the channel body area. S3: Press a portion of the localized reinforced composite base paper into a corrugated sheet with a peak-valley arc transition under the condition that the rectifying layer faces the inside of the predetermined airflow channel, and keep the other portion of the localized reinforced composite base paper as a flat sheet. S4: Corrugated sheets and flat sheets are stacked in correspondence, and the layers are wound and formed with predetermined node strips as interlayer connection areas, so that honeycomb airflow channels are formed between adjacent layers along the carrier axis, and a rotary carrier blank is obtained. S5: Apply radial constraints to the rotor carrier blank and perform low-temperature pre-fixation treatment, medium-temperature curing treatment and high-temperature final shaping treatment in sequence. The medium-temperature curing treatment is used to form an inorganic bonded phase with the inorganic sol impregnated in the predetermined node zone and predetermined side zone. The high-temperature final shaping treatment is used to complete the structural shaping of the rotor carrier blank and obtain the molecular sieve concentration rotor carrier.

[0007] Preferably, in step S1, the rectifying layer is formed using a fine-diameter inorganic fiber slurry, and the skeleton layer is formed using an inorganic fiber slurry with an aspect ratio greater than that of the rectifying layer fibers, so that the surface smoothness of the rectifying layer is higher than that of the skeleton layer.

[0008] Preferably, in step S1, the fibers of the skeleton layer are oriented and filtered or oriented and spread during the formation of the skeleton layer, so that the main orientation direction of the inorganic fibers in the skeleton layer is consistent with the axis of the subsequently formed honeycomb airflow channel.

[0009] Preferably, in S2, the inorganic sol is a silica sol, an aluminum sol, or a silica-alumina composite sol, and the inorganic sol forms a strip-shaped reinforcement region after it is impregnated in the predetermined node strip and the predetermined side strip.

[0010] Preferably, the main area of ​​the channel is not subjected to strip compaction treatment to maintain the permeability of the main area of ​​the channel.

[0011] Preferably, the peaks and valleys of the corrugated sheet are both continuous arc transition structures, adjacent arc transition structures are connected by a smooth transition section, and the rectifying layer is always located on the side of the corrugated sheet facing the airflow channel.

[0012] Preferably, the corrugated sheet and the flat sheet are bonded at a predetermined node strip, and an interlayer connection interface is formed by the inorganic sol in the predetermined node strip, so that adjacent layers form a load-bearing connection node at the predetermined node strip.

[0013] Preferably, after S4 is completed and before S5 begins, the inner and outer ring sidebands of the impeller carrier blank are subjected to secondary narrow band reinforcement treatment, so that the structural strength of the inner and outer ring sidebands is higher than that of the main channel area.

[0014] Preferably, in step S5, the radial constraint is achieved by limiting members set on the inner and outer peripheries of the roller carrier blank, the low-temperature pre-fixing treatment is used to stabilize the winding shape, the medium-temperature curing treatment is used to cure the reinforced structure formed by the secondary narrow-band strengthening treatment, and the high-temperature final shaping treatment is used to complete the overall structural shaping of the roller carrier blank.

[0015] Preferably, after S5 is completed, molecular sieve loading is applied to the main channel area of ​​the rotor carrier, and the molecular sieve loading of the predetermined node band and predetermined side band is lower than that of the main channel area by shielding the predetermined node band and predetermined side band or controlling the molecular sieve impregnation amount of the predetermined node band and predetermined side band.

[0016] In summary, the present invention has the following main beneficial effects: By setting the inorganic fiber composite base paper as a rectifying layer and a skeleton layer along its thickness direction, with the rectifying layer forming the inner wall of the subsequent honeycomb airflow channel and the skeleton layer forming the subsequent carrier load-bearing layer, the channel rectification function and structural load-bearing function are achieved within the same base paper. The rectifying layer improves the smoothness of the channel inner wall, and the corrugated structure with rounded transitions at both peaks and valleys reduces local disturbances and flow resistance during airflow. At the same time, the skeleton layer forms a load-bearing fiber network distributed along the channel axis, which improves the tensile strength, bending strength, and resilience of the carrier during winding, heat treatment, and subsequent operation. This avoids the problem of increased channel resistance caused by simply relying on overall thickening or densification to balance wind resistance and strength.

[0017] By applying strip compaction and inorganic sol impregnation treatment only to predetermined node zones and edge zones, the effect of localized strengthening of subsequent interlayer load-bearing connection paths and boundary stability paths is achieved. By creating locally dense reinforcement zones in the areas corresponding to the wave crest contact line, the wave trough contact line, and the inner and outer ring edge zones, the interlayer connection strength and edge region structural stability are improved. Simultaneously, by not subjecting the main channel area to the same degree of compaction and impregnation treatment, the high permeability of the main channel area is preserved. Therefore, this application does not strengthen the entire base paper as a whole, but concentrates the strengthening effect on the areas that truly bear the functions of force transmission and boundary stability, achieving the effect of improving the structural stability of the carrier without significantly increasing the overall pressure drop.

[0018] By applying radial constraints after winding to form the rotating carrier blank, and then sequentially performing low-temperature pre-fixation, medium-temperature curing, and high-temperature final shaping treatments, the carrier gradually achieves shape stabilization, inorganic phase formation, and overall framework shaping under controlled shrinkage. The medium-temperature curing treatment forms an inorganic bonded phase in the inorganic sol within the predetermined node and edge bands, enhancing the reliability of connections between local load-bearing nodes and boundary stability zones. The high-temperature final shaping treatment completes the overall structural shaping, reducing the risk of ellipticization, edge warping, and local channel collapse during heat treatment. Furthermore, by applying a high degree of molecular sieve loading to the main channel area after carrier shaping, while maintaining a low load on the predetermined node and edge bands, the adsorption functional area is separated from the structural load-bearing area. This ensures the effective adsorption capacity of the main channel area while preventing excessive load on the load-bearing area from affecting connection strength and channel stability. Attached Figure Description

[0019] Figure 1 This is a flowchart of the method of the present invention. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] Example 1 refer to Figure 1 A process for forming a low-wind-resistance, high-stability molecular sieve concentration rotor carrier includes the following steps: S1: Inorganic fiber composite base paper is prepared by wet papermaking process, so that the composite base paper forms a rectification layer and a skeleton layer along the thickness direction. The rectification layer is used to form the inner wall of the subsequent airflow channel, and the skeleton layer is used to form the subsequent carrier load-bearing layer. S2: When the composite base paper is in a wet or semi-wet state, localized reinforcement is applied to the predetermined node strip and predetermined edge strip. The predetermined node strip includes the strip-shaped area corresponding to the crest contact line and the strip-shaped area corresponding to the trough contact line of the subsequent corrugated sheet. The predetermined edge strip includes the area corresponding to the inner ring edge strip and the area corresponding to the outer ring edge strip after subsequent winding and forming. Localized reinforcement includes strip compaction of the predetermined node strip and predetermined edge strip, and impregnation of inorganic sol into the strip compaction area, so that the density of the predetermined node strip and predetermined edge strip is higher than that of the channel body area. S3: Press a portion of the localized reinforced composite base paper into a corrugated sheet with a peak-valley arc transition under the condition that the rectifying layer faces the inside of the predetermined airflow channel, and keep the other portion of the localized reinforced composite base paper as a flat sheet. S4: Corrugated sheets and flat sheets are stacked in correspondence, and the layers are wound and formed with predetermined node strips as interlayer connection areas, so that honeycomb airflow channels are formed between adjacent layers along the carrier axis, and a rotary carrier blank is obtained. S5: Apply radial constraints to the rotor carrier blank and perform low-temperature pre-fixation treatment, medium-temperature curing treatment and high-temperature final shaping treatment in sequence. The medium-temperature curing treatment is used to form an inorganic bonded phase with the inorganic sol impregnated in the predetermined node zone and predetermined side zone. The high-temperature final shaping treatment is used to complete the structural shaping of the rotor carrier blank and obtain the molecular sieve concentration rotor carrier.

[0022] In this embodiment, the molecular sieve concentration rotor carrier is a wound honeycomb channel carrier. The carrier forms multiple honeycomb airflow channels along the axial direction. During operation, the airflow to be treated enters from one end face of the carrier, flows through each honeycomb airflow channel, and then flows out from the other end face. To simultaneously achieve low wind resistance and high stability, the carrier in this embodiment is not formed by integral pressure wave and integral reinforcement of a single layer of homogeneous base paper. Instead, it adopts an inorganic fiber composite base paper with functional division along the thickness direction, and localized reinforcement is only implemented for the subsequent load-bearing path and boundary stability region.

[0023] In this embodiment, the inorganic fiber composite base paper includes a rectifying layer and a skeleton layer. The rectifying layer is located inside the subsequent airflow channel and is used to form a relatively flat inner wall of the channel. The skeleton layer is located on the side opposite to the airflow channel and is used to form a carrier-bearing layer. The rectifying layer and the skeleton layer are continuously deposited during the wet papermaking stage and directly composited in a wet state to form an integrated wet sheet structure. It is not a subsequent bonding structure of two independent paper layers, so there is no additional bonding interface between the layers.

[0024] To avoid ambiguity in terminology, the following limitations are made to some terms used in this embodiment. "Fine-diameter inorganic fibers" refers to inorganic fibers in the rectifying layer having an average fiber diameter smaller than those in the skeleton layer within the same composite base paper. "Inorganic fibers with a higher aspect ratio" refers to inorganic fibers in the skeleton layer having an average aspect ratio greater than those in the rectifying layer within the same composite base paper. "Surface smoothness higher than the skeleton layer" means that, under the same sampling length and measurement conditions, the arithmetic mean roughness of the rectifying layer is less than that of the skeleton layer, thus determining that the surface smoothness of the rectifying layer is higher than that of the skeleton layer.

[0025] In this embodiment, the rectifying layer is formed using fine-diameter inorganic fiber slurry, and the skeleton layer is formed using inorganic fiber slurry with a high aspect ratio. The fine-diameter inorganic fibers improve the surface uniformity of the rectifying layer, enabling it to form a smoother channel inner wall after subsequent forming. The inorganic fibers with a high aspect ratio form an overlapping load-bearing network within the skeleton layer, improving the tensile, flexural, and resilience of the base paper in the winding direction, channel axial direction, and radial direction. The inorganic fibers used in both the rectifying layer and the skeleton layer can be selected from one or more of glass fiber, aluminosilicate fiber, and alumina fiber. To improve paper stability, inorganic fillers and temporary paper-forming aids can also be added to the slurry. The inorganic fillers can be selected from one or more of kaolin, alumina powder, and silica powder, while the temporary paper-forming aids improve wet-sheet formability and the initial bonding state between fibers.

[0026] In this embodiment, the composite base paper is formed using a continuous wet papermaking process. First, the rectifying layer slurry is fed into the paper forming zone to form a first wet layer. Then, the skeleton layer slurry is deposited on the first wet layer to form a second wet layer, allowing the rectifying layer and skeleton layer to be directly composited in a wet state. To ensure the skeleton layer forms a load-bearing network along the axial direction of the subsequent honeycomb airflow channels, the slurry flow direction and filtration direction are controlled during the skeleton layer formation process, causing the long fibers in the skeleton layer to form a primary orientation distribution along the length of the base paper. Since the length direction of the base paper after winding corresponds to the axial direction of the honeycomb airflow channels, the primary orientation direction of the skeleton layer fibers is consistent with the axial direction of the subsequently formed honeycomb airflow channels.

[0027] After the composite base paper is formed, it is not immediately and completely dried, but enters the subsequent localized strengthening process in a wet or semi-wet state. To avoid ambiguity in the description of wet or semi-wet state, the wet or semi-wet state referred to in this embodiment means that the composite base paper can be transferred as a whole without breaking under its own weight, and can still undergo compression deformation in the thickness direction under the action of local pressure rollers, and does not show brittle cracks after local compression. In other words, as long as the composite base paper still retains sufficient plasticity to support local compaction and local inorganic sol wetting, it can be regarded as wet or semi-wet state as referred to in this application.

[0028] In this embodiment, when the composite base paper is in a wet or semi-wet state, localized reinforcement is applied to the predetermined node strip and predetermined edge strip. The predetermined node strip refers to the strip-shaped area that forms the interlayer load-bearing connection node after the corrugated sheet and flat sheet are subsequently bonded together, specifically including the strip-shaped area corresponding to the crest contact line and the strip-shaped area corresponding to the trough contact line. The predetermined edge strip refers to the strip-shaped area located at the inner and outer ring edges after subsequent winding and forming, which undertakes boundary stabilization, specifically including the area corresponding to the inner ring edge strip and the area corresponding to the outer ring edge strip. To facilitate the determination of their positions by those skilled in the art, the position of the predetermined node strip is determined centered on the theoretical crest contact line and theoretical trough contact line after the corrugated sheet is formed, and is based on the ability to completely cover the subsequent actual interlayer contact bandwidth; the position of the predetermined edge strip is based on the strip-shaped range extending from the inner and outer peripheral edges towards the main channel area after winding, and continuously covering the force transmission path of the outermost interlayer connection node.

[0029] In this embodiment, the main channel region refers to the area located between adjacent predetermined node strips, which mainly forms the axial airflow channel wall after winding. The main channel region does not bear the primary interlayer load-bearing connection function, but mainly serves the function of airflow passage and subsequent molecular sieve loading. Unlike the predetermined node strips and predetermined side strips, the main channel region is not subjected to strip compaction treatment, nor is it subjected to the same degree of local inorganic sol impregnation, thus retaining high permeability.

[0030] The localized strengthening process comprises two consecutive actions. First, a strip compaction is performed on the predetermined node strip and predetermined side strip. Second, an inorganic sol is impregnated into the strip compaction area. The strip compaction can be achieved using a strip roller, a strip die, or a localized linear compaction device, and its function is to reduce the thickness of the corresponding strip area, increase the fiber contact area, and decrease the local porosity. The inorganic sol can be silica sol, aluminum sol, or a silica-alumina composite sol, and can be applied by localized spraying, localized roller coating, localized scraping, or localized impregnation. During this stage, the inorganic sol enters the fiber pores of the strip compaction area and subsequently undergoes a medium-temperature curing treatment to form an inorganic bound phase.

[0031] To facilitate process verification, the local compaction rate can be used to characterize the degree of strip compaction in this embodiment. The local compaction rate is expressed by the following formula: Where is the local compaction rate of the i-th strip region, is the thickness of the strip region before compaction, and is the thickness of the strip region after compaction. As long as the local compaction rate corresponding to the predetermined node strip and the predetermined side strip is greater than the corresponding position of the main channel region, it can be determined that localized compaction has been formed. This formula is only used for process verification during implementation and is not used to limit the specific numerical range in the claims.

[0032] After localization strengthening, a portion of the composite base paper is prepared into a corrugated sheet, while the other portion remains as a flat sheet. During corrugation sheet formation, the rectifying layer faces the inner side of the predetermined airflow channel, ensuring that the rectifying layer consistently forms the inner wall of the airflow channel in the subsequent carrier. The corrugated sheet does not employ sharp-angled corrugations, but rather a corrugated structure with rounded transitions at both peaks and valleys. Adjacent arcs are connected by continuous transition sections to avoid stress concentration and localized eddies at sharp angles. To avoid ambiguity in geometric terminology, the continuous transition section referred to in this embodiment refers to a segment structure that connects adjacent arc sections with continuous curvature changes and no obvious fold lines. As long as there are no sharp angles between the peaks and valleys, and no abrupt fold lines between adjacent arcs, it can be considered a peak-valley arc transition structure as described in this application.

[0033] The flat sheet is formed directly from another portion of composite base paper that has undergone localized strengthening. The flat sheet retains the hierarchical relationship between the rectifying layer and the skeleton layer, and forms the other side wall of the honeycomb airflow channel after being stacked with the corrugated sheet. The corrugated sheet and the flat sheet are arranged correspondingly in the dimensional direction, so that the crest contact line and the trough contact line form predetermined nodal bands when they are attached to the flat sheet.

[0034] The process then involves winding. During winding, corrugated sheets and flat sheets are alternately stacked, with predetermined nodal zones serving as interlayer connection areas, creating honeycomb airflow channels that run through the carrier axis between adjacent layers. Since the predetermined nodal zones have been locally compacted and impregnated with inorganic sol, they serve both as interlayer bonding points during winding and as a stable inorganic bonding phase during the subsequent medium-temperature curing stage. This results in load-bearing connection nodes between adjacent layers at the predetermined nodal zones. These load-bearing connection nodes are localized connection areas capable of continuously transmitting interlayer forces under winding constraints, heat treatment shrinkage, and subsequent operational loads, rather than simple point-contact areas.

[0035] After winding, a rotary carrier blank is obtained. To prevent the blank from becoming elliptical, edge warping, or local channel collapse due to free shrinkage during heat treatment, this embodiment applies radial constraints to the rotary carrier blank before heat treatment. These radial constraints are achieved through limiting members located on the inner and outer circumferences of the blank. The inner circumferential limiting member maintains the roundness of the inner ring and restricts disordered shrinkage within the inner circumference, while the outer circumferential limiting member maintains the roundness of the outer ring and restricts local bulging on the outer circumference. These limiting members can be heat-resistant rings, heat-resistant clamping frames, or detachable support rings. The radial constraints allow controlled shrinkage of the blank within a predetermined range, rather than completely preventing dimensional changes.

[0036] Under radial constraint, the roll carrier blank undergoes low-temperature pre-fixation, medium-temperature curing, and high-temperature final shaping treatment sequentially. To avoid ambiguity in the descriptions of low-temperature, medium-temperature, and high-temperature treatments, in this embodiment, the three heat treatment stages are not named based on arbitrary absolute temperatures, but rather on the material state changes of the same batch of composite base paper and inorganic sol system during the heat treatment process. Specifically, the low-temperature pre-fixation treatment refers to the heat treatment stage that reaches the first judgment state, where the free water in the composite base paper has been largely removed, the blank can maintain its winding geometry after the external transfer support is removed, and the inorganic sol has not yet formed a continuous inorganic bonded phase. The medium-temperature curing treatment refers to the heat treatment stage that reaches the second judgment state, where the inorganic sol in the predetermined node zone and predetermined edge zone has formed a continuous inorganic bonded phase, the temporary paper-forming additives lose their wet bonding function or begin thermal failure, and the blank has not yet reached final dimensional stability. High-temperature final setting treatment refers to the heat treatment stage that reaches the third judgment state. This third judgment state is characterized by the removal or ineffectiveness of temporary paper-forming additives, stable shrinkage of the preform, and stable maintenance of the overall geometry and interlayer bonding of the carrier. The above three judgment states can be determined by thermal analysis, weight loss testing, and constrained firing shrinkage testing of the same batch of composite base paper and inorganic sol. As long as the above judgment states are met, it belongs to the low-temperature pre-fixation treatment, medium-temperature curing treatment, and high-temperature final setting treatment referred to in this application.

[0037] The low-temperature pre-fixing treatment is mainly used to stabilize the winding shape and prevent interlayer relative slippage of the wet or semi-wet preform during subsequent heating and handling. The medium-temperature curing treatment is mainly used to form an inorganic bonding phase in the inorganic sol in the predetermined node strip and predetermined side strip, thereby forming a stable load-bearing structure in the local reinforcement area. The high-temperature final shaping treatment is mainly used to complete the overall structural shaping of the carrier, so that the rectifying layer, skeleton layer, node strip reinforcement area and side strip reinforcement area together form a stable inorganic carrier skeleton.

[0038] In this embodiment, after winding and before low-temperature pre-fixation, a secondary narrow-strip reinforcement treatment can be applied to the inner and outer ring sidebands of the rotor carrier blank to further improve circumferential stability and radial deformation resistance. To avoid overly broad descriptions of the secondary narrow-strip reinforcement treatment, this embodiment refers to a further localized reinforcement treatment applied only to the inner and outer ring sidebands. Preferably, this is implemented by applying a localized inorganic sol supplement to the inner and outer ring sidebands, combined with localized compaction using an annular rolling element or a strip-shaped pressing element, resulting in a secondary reinforcement structure stronger than the main channel area. This secondary narrow-strip reinforcement treatment does not act on the main channel area, nor does it cover the entire channel wall of the flat sheet and corrugated sheet, thus avoiding overall densification and blockage. The narrow strip refers to a strip-shaped reinforcement area that covers only the edge load-bearing area relative to the entire carrier width, with its width sufficient to continuously cover the force transmission path of the outermost interlayer connection node on the inner or outer periphery.

[0039] The rotating carrier formed after the above treatment has the following structural relationship: the rectifying layer is always located inside the honeycomb airflow channel and forms a relatively flat inner wall of the channel; the skeleton layer is located on the side opposite to the airflow channel and forms a load-bearing fiber network; the predetermined node band and predetermined side band form a locally dense reinforcement zone; the main channel area maintains high permeability; and the entire carrier completes a continuous shaping process from initial forming to inorganic phase formation and then to overall structural stability under radial constraint. Therefore, this embodiment does not involve mixing molecular sieves, fibers, and binders to form a single homogeneous paperboard, nor does it involve impregnating the entire paperboard with inorganic sol and sintering it as a whole. Instead, it first forms a composite base paper with functional division, then implements localized reinforcement on the subsequent load-bearing areas, and forms the inorganic phase and final skeleton structure in stages under constraint.

[0040] Example 2 After the rotor carrier formed in Example 1 completes its high-temperature final setting, it is subjected to molecular sieve loading. The molecular sieve loading does not employ a uniform, whole-carrier loading method, but rather a differentiated molecular sieve loading method with high loading in the main channel region and low loading in predetermined node and edge zones. The purpose is to prioritize adsorption in the main channel region and prioritize structural connection and boundary stabilization in the predetermined node and edge zones, thereby preventing excessive molecular sieve buildup in the load-bearing area from affecting connection strength and local permeability.

[0041] In this embodiment, differentiated molecular sieve loading can be achieved through either of the following two methods. The first method is a masking loading method, in which masking components are set on predetermined node zones and predetermined side zones before molecular sieve impregnation, spraying, or slurry coating, so that the molecular sieve slurry or molecular sieve precursor liquid mainly enters the main channel area, and does not form an equal degree of deposition in the predetermined node zones and predetermined side zones. The second method is a controlled wetting method, in which, without completely masking the predetermined node zones and predetermined side zones, the molecular sieve loading of the predetermined node zones and predetermined side zones is lower than that of the main channel area by controlling the wetting time, wetting depth, spraying angle, or application amount per unit area of ​​the node zones and predetermined side zones.

[0042] To avoid ambiguity in describing the load capacity as "low," this embodiment uses the load capacity per unit area of ​​the integral molecular sieve as the criterion for determination. The load capacity per unit area of ​​the integral molecular sieve is expressed by the following formula: Wherein, is the molecular sieve loading per unit area of ​​the i-th region, is the mass of the region before loading, is the mass of the region after loading, and is the surface area of ​​the region. If the molecular sieve loading of the predetermined node band and predetermined side band is less than that of the channel main body region, it can be determined that the molecular sieve loading of the predetermined node band and predetermined side band is lower than that of the channel main body region. If the unit volume loading is used as the criterion, as long as the conclusion is also that the unit volume loading of the predetermined node band and predetermined side band is less than that of the channel main body region, it also falls under the category of the loading being lower than that described in this application.

[0043] In this embodiment, the molecular sieve used can be a molecular sieve material suitable for organic waste gas concentration rotors, and the loading method can be impregnation loading, slurry coating loading, or in-situ growth loading. If impregnation loading is used, directional impregnation or partial shielding is preferred to avoid excessive adsorption of molecular sieve slurry by the nodal and edge bands. If slurry coating loading is used, directional spraying or brushing along the main channel area is preferred to achieve a higher molecular sieve deposition in the main area, while maintaining a lower deposition in the nodal and edge bands. If in-situ growth loading is used, the molecular sieve can preferentially grow in the main channel area by pre-treating the surface of the predetermined nodal and edge bands or reducing their surface active site density.

[0044] Through the aforementioned differentiated load-bearing method, the main channel area primarily undertakes the adsorption function, while the predetermined node strip and predetermined side strip primarily undertake the structural function. In this way, the adsorption zone and the load-bearing zone are spatially separated, avoiding the contradictions caused by the complete overlap of the adsorption and load-bearing functional zones in existing integral mixing or impregnation routes.

[0045] The working principle of this application is as follows: First, a wet papermaking process is used to form an integrated inorganic fiber composite base paper consisting of a rectifying layer and a skeleton layer. The rectifying layer is used to form the inner wall of the honeycomb airflow channel after subsequent molding to improve the flatness of the channel wall. The skeleton layer is used to bear structural stress during subsequent winding, heat treatment, and operation. Thus, the channel rectifying function and structural load-bearing function are divided in the thickness direction of the base paper. Subsequently, when the composite base paper is in a wet or semi-wet state, only the predetermined node strips that will serve as the interlayer load-bearing connection path and the predetermined edge strips that will serve as the boundary stabilization path are subjected to strip compaction and inorganic sol impregnation treatment. This makes the predetermined node strips and predetermined edge strips form locally dense reinforcement zones, while the main channel area located between adjacent node strips is not subjected to the same degree of compaction and impregnation treatment to maintain the high permeability of the main channel area. Subsequently, the composite base paper facing the inner side of the rectifier layer towards the predetermined airflow channel is pressed into a corrugated sheet with rounded transitions at both the peak and valley. This corrugated sheet is then alternately stacked with a flat sheet and wound up, so that the corrugated sheet and the flat sheet form a continuous interlayer load-bearing connection node at the predetermined node zone. At the same time, a honeycomb airflow channel is formed between adjacent layers that runs through the carrier axis.

[0046] After the rotating carrier blank is formed by winding, radial constraints are applied to the blank by limiting members set on the inner and outer circumferences. This allows the blank to undergo a series of processes under controlled shrinkage: low-temperature pre-fixation, medium-temperature curing, and high-temperature final shaping. The low-temperature pre-fixation stabilizes the initial geometry after winding; the medium-temperature curing causes the inorganic sol in the predetermined node and edge bands to form an inorganic bonding phase, enhancing interlayer bonding strength and boundary stability; and the high-temperature final shaping completes the overall framework structure shaping, preventing ellipticization, edge warping, or local channel collapse under free shrinkage conditions. Finally, after carrier shaping, a higher degree of molecular sieve loading is applied to the main channel region, while the molecular sieve loading in the predetermined node and edge bands is lower than that in the main channel region. This ensures that the main channel region primarily performs adsorption functions, while the predetermined node and edge bands primarily perform structural connection and boundary stabilization functions. Thus, this application achieves both low airflow resistance and high structural stability without relying on the overall densification of the entire base paper through the synergistic cooperation of layered paper forming, localized strengthening, circular arc corrugation forming, radial constraint shaping, and differentiated molecular sieve loading.

[0047] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A molding process for a low-wind-resistance, high-stability molecular sieve concentration rotor carrier, characterized in that, Includes the following steps: S1: Inorganic fiber composite base paper is prepared by wet papermaking process, so that the composite base paper forms a rectification layer and a skeleton layer along the thickness direction. The rectification layer is used to form the inner wall of the subsequent airflow channel, and the skeleton layer is used to form the subsequent carrier load-bearing layer. S2: When the composite base paper is in a wet or semi-wet state, localized reinforcement is applied to the predetermined node strip and predetermined edge strip. The predetermined node strip includes the strip-shaped area corresponding to the crest contact line and the strip-shaped area corresponding to the trough contact line of the subsequent corrugated sheet. The predetermined edge strip includes the area corresponding to the inner ring edge strip and the area corresponding to the outer ring edge strip after subsequent winding and forming. Localized reinforcement includes strip compaction of the predetermined node strip and predetermined edge strip, and impregnation of inorganic sol into the strip compaction area, so that the density of the predetermined node strip and predetermined edge strip is higher than that of the channel body area. S3: Press a portion of the localized reinforced composite base paper into a corrugated sheet with a peak-valley arc transition under the condition that the rectifying layer faces the inside of the predetermined airflow channel, and keep the other portion of the localized reinforced composite base paper as a flat sheet. S4: Corrugated sheets and flat sheets are stacked in correspondence, and the layers are wound and formed with predetermined node strips as interlayer connection areas, so that honeycomb airflow channels are formed between adjacent layers along the carrier axis, and a rotary carrier blank is obtained. S5: Apply radial constraints to the rotor carrier blank and perform low-temperature pre-fixation treatment, medium-temperature curing treatment and high-temperature final shaping treatment in sequence. The medium-temperature curing treatment is used to form an inorganic bonded phase with the inorganic sol impregnated in the predetermined node zone and predetermined side zone. The high-temperature final shaping treatment is used to complete the structural shaping of the rotor carrier blank and obtain the molecular sieve concentration rotor carrier.

2. The molding process for a low-wind-resistance, high-stability molecular sieve concentration rotor carrier according to claim 1, characterized in that, In step S1, the rectifying layer is formed using fine-diameter inorganic fiber slurry, and the skeleton layer is formed using inorganic fiber slurry with an aspect ratio greater than that of the rectifying layer fibers, so that the surface smoothness of the rectifying layer is higher than that of the skeleton layer.

3. The molding process for a low-wind-resistance, high-stability molecular sieve concentration rotor carrier according to claim 2, characterized in that, In step S1, during the formation of the skeleton layer, the fibers of the skeleton layer are oriented and filtered or oriented and spread so that the main orientation direction of the inorganic fibers in the skeleton layer is consistent with the axis of the subsequently formed honeycomb airflow channel.

4. The molding process for a low-wind-resistance, high-stability molecular sieve concentration rotor carrier according to claim 3, characterized in that, In S2, the inorganic sol is a silica sol, an aluminum sol, or a silica-alumina composite sol, and the inorganic sol forms a strip-shaped reinforcement region after it is impregnated in the predetermined node strip and the predetermined side strip.

5. The molding process for a low-wind-resistance, high-stability molecular sieve concentration rotor carrier according to claim 4, characterized in that, The main area of ​​the channel is not subjected to strip compaction treatment in order to maintain the permeability of the main area of ​​the channel.

6. The molding process for a low-wind-resistance, high-stability molecular sieve concentration rotor carrier according to claim 5, characterized in that, The peaks and valleys of the corrugated sheet are both continuous arc transition structures, and adjacent arc transition structures are connected by a smooth transition section. The rectifier layer is always located on the side of the corrugated sheet facing the airflow channel.

7. The molding process for a low-wind-resistance, high-stability molecular sieve concentration rotor carrier according to claim 6, characterized in that, The corrugated sheet and the flat sheet are bonded together at a predetermined node strip, and an interlayer connection interface is formed by the inorganic sol in the predetermined node strip, so that the adjacent layers form a load-bearing connection node at the predetermined node strip.

8. The molding process for a low-wind-resistance, high-stability molecular sieve concentration rotor carrier according to claim 7, characterized in that, After S4 is completed and before S5 begins, the inner and outer ring sidebands of the impeller carrier blank are subjected to secondary narrow band reinforcement treatment, so that the structural strength of the inner and outer ring sidebands is higher than that of the main channel area.

9. The molding process for a low-wind-resistance, high-stability molecular sieve concentration rotor carrier according to claim 8, characterized in that, In S5, the radial constraint is achieved by limiting members set on the inner and outer peripheries of the roller carrier blank. The low-temperature pre-fixing treatment is used to stabilize the winding shape, the medium-temperature curing treatment is used to cure the reinforced structure formed by the secondary narrow band strengthening treatment, and the high-temperature final shaping treatment is used to complete the overall structural shaping of the roller carrier blank.

10. The molding process for a low-wind-resistance, high-stability molecular sieve concentration rotor carrier according to claim 9, characterized in that, After S5 is completed, molecular sieve loading is applied to the main channel area of ​​the rotor carrier, and the molecular sieve loading of the predetermined node band and predetermined side band is lower than that of the main channel area by shielding the predetermined node band and predetermined side band or controlling the molecular sieve impregnation amount of the predetermined node band and predetermined side band.

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